Device for the additive manufacturing of three-dimensional objects from powdery building material

ABSTRACT

Methods of additively manufacturing a three-dimensional object include receiving manufacturing data from a memory chip physically associated with an exchangeable container configured for use with a system for additively manufacturing three-dimensional objects, and controlling a first operation comprising an operation of an active element of the exchangeable container and/or a second operation comprising an operation of a transporting path configured to transport the exchangeable container within the system for additively manufacturing three-dimensional objects, in which controlling the first operation and/or the second operation is based at least in part on an object to be and/or being additively manufactured using the exchangeable container.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 15/312,175, filed Nov. 17, 2016, which was a U.S. 371 National Stage entry of International Application Serial No. PCT/DE2015/100169, filed Apr. 23, 2015, which claims priority to German Application No. 10 2014 007 408.0, filed May 21, 2014, the contents of which are incorporated herein by reference in their entirety as if set forth verbatim.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure are described with reference to the figures, in which:

FIG. 1 shows a schematic representation of a device according to the present disclosure with a plurality of transporting paths, processing stations and storage positions;

FIG. 2 shows a schematic view of an exchangeable container with two indicated positions of a readable memory chip;

FIG. 3 shows a schematic representation of an exchangeable container with a memory chip incorporated in a powder bed;

FIG. 4 shows a schematic sectional representation through a building chamber with an object built up therein, to which a memory chip is fastened by means of a connecting web.

DETAILED DESCRIPTION

The present disclosure relates to a device for the additive manufacturing of three-dimensional objects from powdery building material by introducing radiation energy. Such devices are referred to in particular as laser sintering or laser melting machines and have a housing with a process chamber, in which a building space or an exchangeable container with a height-adjustable building platform is arranged.

During the building operation, a thin layer of powdery building material is applied to the building platform and subsequently solidified region by region in accordance with a prescribed structure of the component to be produced. This operation is continued by newly coating the previous powder layer or solidified partial layer each time until the three-dimensional component is completed in a layered manner of building under the effect of radiation.

In the case of such devices, it has already become known to use so-called exchangeable containers, which can be moved into a process chamber in order to carry out the building operation and, after completion of the building operation, can be removed again from the process chamber with the object located in it. These exchangeable containers are then brought into a so-called unpacking station or further processing station and the workpiece is further processed appropriately there.

Such a device is disclosed for example by DE 10 2009 036153 A1.

The present disclosure addresses the problem of developing a device in such a way that, after the building operation, an assignment to a customer, an analysis and/or further transport and/or specific further processing of the workpiece can be performed at other stations on an automated, object-individualized basis.

This problem is solved by providing a memory chip, which can be removed with the exchangeable container and/or with the built object from the process chamber of the device, is assigned to the object, can be read by means of an electronic reading device and has stored on it manufacturing data belonging to the additive manufacturing process, subsequent processing steps and/or following processing stations and/or for automatically storing a building record and/or for controlling items of processing equipment, transporting paths and/or storage positions.

In accordance with the present disclosure, the object manufactured in the device is provided with a memory chip, which is either integrated in the exchangeable container or detachably or undetachably fastened to it or else lies in the unsolidified building material within the building chamber, or even is connected to the object by an additive solidifying step or is arranged in a building platform or supporting structure. In this chip there may firstly be input by a writing device building data that are suitable for undoing the building operation that has been performed in the device, in the sense of “reverse engineering”, in order to establish whether the object manufactured in the device could for example have internal structural faults and the like. Building data are for example the power of the laser, coating data, atmospheric data in the building chamber or the temperature, but in particular also molten pool temperatures or molten pool sizes in the region of the focal point of the laser on the powder layer, or other data that are suitable for providing information about a building operation that has already been carried out.

In addition, customer information may be stored in the same chip, for example a customer number, manufacturing data, delivery date and delivery location. Here, too, there are no limits to customer or delivery data.

It is also possible to use the chip for controlling subsequent processing steps, if the manufactured object is for example subjected to a special surface processing or is to be transported to an engraving device. Processing equipment following the manufacturing device, such as milling stations, thermal treatment stations, polishing stations, handling stations, an optical measuring station or else a disinfection station for the disinfecting treatment of the component and the like, may be automatically controlled by the chip.

The transporting path to such processing equipment that has to be covered between the actual manufacturing device and the processing devices may likewise be traveled specifically by the memory chip, so that manual intervention is not required during the transport of the object to further processing stations. In the end, it is also possible to store on the chip a position in a storage area that is then automatically moved to by a transporting device. If the chip is an RFID chip, when someone enters the storage space an inventory can be immediately compiled by an RFID reading device and it can be established which objects that have already been manufactured are where in the storage space and which objects are to be retrieved and delivered at a certain point in time.

Finally, it is also possible within the scope of the present disclosure to use the memory chip for controlling active elements of the exchangeable container that is provided with the memory chip. In particular, drive motors for moving the exchangeable container, servomotors for the height adjustment of the building platform, heating elements, cooling elements, ventilating motors, suction extraction equipment and the like that are integrated in the exchangeable container can be controlled. Since the memory chip can be programmed individually for each building operation, the control of the active elements of the exchangeable container can be adapted precisely to the building process and subsequent treatment steps.

All of these data can be recorded on one and the same chip, it also being within the scope of the present disclosure however to provide a plurality of readable memory chips that can be provided for the exchangeable container or the built project and can be removed with the latter from the process chamber of the device. The programming may be performed in the device itself, but it is also possible to provide preprogrammed chips, which are already fully or partially preprogrammed and for example are then just loaded with the manufacturing data.

The laser sintering or laser melting machine may be provided with an input device, for example a card reader or some other input device that is suitable for programming the memory chip more or less completely.

After the manufacturing operation, the exchangeable container is moved out of the device and can be brought on intended transporting paths to such other processing stations that are stored on the memory chip as an intermediate station or destination station. An intermediate station would be for example an intermediate processing station, a destination station would be a storage location.

In the laser sintering or laser melting device and in other processing stations, such as for example milling stations or thermal treatment stations, or else on sections of the route of the exchangeable container or of the object between the device and the other processing stations or storage sites, electronic reading devices that interact with the memory chip may be arranged, these being suitable for controlling diverting equipment, in order that the object or the exchangeable container is taken to the correct station.

In principle it is also possible to couple with the memory chip a processor that interacts with at least one sensor element inside the exchangeable container. As a result, physical data, such as pressure, temperature, time, acceleration values and the like, can be established, in order to record on the memory chip whether after the manufacturing operation the object was affected by any external circumstances that lead to the object being damaged. An acceleration sensor may for example detect a heavy collision, with the potential to lead to breakage or partial breakage of an object.

The device 1 represented in FIG. 1 serves for manufacturing three-dimensional objects 2 from powdery building material 3 by introducing radiation energy. It is in particular a laser sintering or laser melting device. Accommodated in a housing 4 is a process chamber 5, in which a building space or an exchangeable container 6 is arranged, with a height-adjustable building platform to which the powdery building material intended for solidifying by means of radiation energy can be applied.

It is also shown in FIG. 1 that, along with the actual manufacturing device, also provided are other processing stations 7, storage stations 8, at least one unpacking station 9, a testing station 10 and for example an engraving station 11, which are all connected to one another by means of transporting paths 12 in such a way that either the exchangeable container 6 or the object 2 freed from the powder bed can be transported to the various processing stations 7, storage locations 8 or other positions along the transporting paths 12. Automatically controlled transporting carriages, conveyor belts or other transporting mechanisms that are known as prior art and are suitable may be used for this.

In order to control the movements to the various transporting paths 12 or items of processing equipment or storage positions, either a memory chip 16 is provided, which can be removed with the exchangeable container 6 or with the built object 2 from the process chamber of the device 1, can be read by means of an electronic reading device 15 and has stored on it manufacturing data belonging to the additive manufacturing process and/or subsequent processing steps or the processing stations for automatically controlling processing equipment, transporting paths and/or storage positions.

The assignment between the exchangeable container 6 and the memory chip 16 may be performed in various ways.

In FIG. 1 it is shown that the memory chip 16 is attached to an outer wall of the exchangeable container 6.

In FIG. 2 it is indicated that the memory chip 16 can be inserted into pocket-like recesses 17 of the exchangeable container 6 and for example be locked there.

In FIG. 3 it is shown that it is also adequate to place the memory chip 16 into the powder bed 18 of the building material 3 and leave it there, so that the memory chip 16 can be removed with the exchangeable container 6 from the process chamber. For temporarily fixing the memory chip 16, it may for example be introduced into a housing with anchoring projections that extend into the powder bed.

Another possibility for the arrangement of the memory chip 16 is schematically represented in FIG. 4. There, the memory chip 16 is connected to the object 2 by means of a web 25, so that a fixed assignment between the memory chip 16 and the object 2 is retained even after unpacking the object from the building material 3. It is within the scope of the present disclosure to provide along with the memory chip 16, which is connected to the object, one or more memory chips 26 in connection with the exchangeable container 6. The memory chips 26 may for example be used for influencing diverting equipment of the transporting paths 12; by contrast, the memory chip 16 on the object 2 contains customer data, process data, such as for example manufacturing temperatures, molten pool temperatures and the like. It is of course possible to record all data on both memory chips 16, 26 and read and use the data appropriately.

In FIG. 4 it is shown that the memory chip can also be accommodated in a building plate 27, onto which powdery building material 3 is deposited in layers during the building operation and solidified there, in order to build the first layers of the object 2.

In FIG. 1 it is also shown that in the process chamber 5 there may be provided a programming device 30, which is in connection with an input unit 31 in order to load appropriate data onto the memory chip 16.

It is also within the scope of the present disclosure to connect to the memory chip 16 at least one processor 40, which interacts with at least one sensor element inside the exchangeable container 6, in order for example to register or report harmful accelerations, temperatures or other influences on the object 2.

LIST OF DESIGNATIONS

-   1 Device -   2 Object -   3 Building material -   4 Housing -   5 Process chamber -   6 Exchangeable container -   7 Processing station -   8 Storage position -   9 Unpacking station -   10 Testing station -   11 Engraving station -   12 Transporting path -   15 Reading device -   16 Memory chip -   25 Web -   26 Memory chip -   27 Building plate -   30 Programming device -   31 Input unit -   40 Processor 

1-17. (canceled)
 18. A method of additively manufacturing a three-dimensional object, the method comprising: receiving manufacturing data from a memory chip physically associated with an exchangeable container configured for use with a system for additively manufacturing three-dimensional objects; and controlling a first operation comprising an operation of an active element of the exchangeable container and/or controlling a second operation comprising an operation of a transporting path configured to transport the exchangeable container within the system for additively manufacturing three-dimensional objects; wherein controlling the first operation and/or controlling the second operation is based at least in part on an object to be and/or being additively manufactured using the exchangeable container.
 19. The method of claim 18, wherein the active element of the exchangeable container comprises: a servomotor, a heating element, a cooling element, a ventilating motor, or a suction extraction element.
 20. The method of claim 18 wherein controlling the first operation comprises: adjusting a height of a building platform within the exchangeable container using the active element of the exchangeable container.
 21. The method of claim 18 wherein controlling the first operation comprises: heating the exchangeable container using the active element of the exchangeable container; and/or cooling the exchangeable container using the active element of the exchangeable container.
 22. The method of claim 18 wherein controlling the first operation comprises: venting the exchangeable container using the active element of the exchangeable container.
 23. The method of claim 18 comprising: controlling a first operation based at least in part on the manufacturing data from the memory chip; and/or controlling the second operation based at least in part on the manufacturing data from the memory chip.
 24. The method of claim 18 comprising: determining the object to be and/or being additively manufactured using the exchangeable container based at least in part on the manufacturing data from the memory chip.
 25. The method of claim 18 comprising: associating the manufacturing data from the memory chip with the object to be and/or being additively manufactured using the exchangeable container.
 26. The method of claim 18 comprising: configuring the manufacturing data on the memory chip for controlling the first operation; and/or configuring the manufacturing data on the memory chip for controlling the second operation.
 27. The method of claim 18, comprising controlling the first operation during an additive manufacturing process and/or one or more subsequent processing steps.
 28. The method of claim 18, comprising controlling the second operation during movement of the exchangeable container along the transporting path.
 29. The method of claim 18, wherein the transporting path is configured to move the exchangeable container to one or more of a plurality of locations, the plurality of locations comprising one or more devices for additively manufacturing three-dimensional objects, one or more processing stations, and/or one or more a storage stations.
 30. The method of claim 29, comprising: reading the manufacturing data from the memory chip using one or more electronic reading devices, wherein the one or more electronic reading devices are located at a device for additively manufacturing three-dimensional objects, at a processing station, at a storage station, and/or along the transporting path.
 31. The method of claim 29, wherein the one or more processing stations comprises: a milling station, a thermal treatment station, a polishing station, a handling station, an optical measuring station, and/or a disinfection station.
 32. The method of claim 18, comprising: identifying the exchangeable container from among a plurality of exchangeable containers based at least in part on the manufacturing data from the memory chip.
 33. The method of claim 32, comprising: deploying the exchangeable container from a storage site.
 34. The method of claim 18, wherein controlling the second operation comprises controlling a transporting mechanism.
 35. The method of claim 18, wherein the transporting mechanism comprises a carriage, a conveyor belt, or a diverting device.
 36. The method of claim 18, wherein the memory chip is integrated within the exchangeable container or detachably or undetachably fastened to the exchangeable container, and/or disposed within a portion of unsolidified building material within the exchangeable container, and/or connected to or integrated within a building plate disposed within the exchangeable container.
 37. A computer-readable medium comprising computer-executable instructions, which when executed by a processor associated with a system for additively manufacturing three-dimensional objects, causes the processor to perform a method comprising: receiving manufacturing data from a memory chip physically associated with an exchangeable container configured for use with a system for additively manufacturing three-dimensional objects; and controlling a first operation comprising an operation of an active element of the exchangeable container and/or controlling a second operation comprising an operation of a transporting path configured to transport the exchangeable container within the system for additively manufacturing three-dimensional objects; wherein controlling the first operation and/or controlling the second operation is based at least in part on an object to be and/or being additively manufactured using the exchangeable container. 